Motor

ABSTRACT

A motor  11  is used for an electric power steering apparatus or the like. A power supply section  31  from which a wire harness  33  electrically connected to a brush  23  is led along the axial direction of an output shaft  12  is provided on an end surface  25   a  of a bracket  25  of the motor  11  in one end side of the bracket. The power supply section  31  has a power supply terminal  44  provided in a brush holder unit  24  and extending in the axial direction, a connection hole  37  opened in the end surface  25   a  and containing the power supply terminal  44,  a terminal unit  32  attached to the connection hole  37  and having a joint terminal  34,  and an O-ring inserted between the terminal unit  32  and the end surface  25   a.  The end surface  25   a  is provided with a counter lock portion  29,  and the motor  11  is positioned and fixed to a gearbox. As a result, wiring can be arranged in the axial direction without bending the wire harness.

BACKGROUND OF THE INVENTION

[0001] 1. Field of the Invention

[0002] The present invention relates to a motor in which a power supply line is led from a bracket containing a brush holder.

[0003] 2. Related Art Statement

[0004] In a small-size motor for an electric power steering apparatus (hereinafter referred to as an EPS), an electric power is supplied to the motor from a battery through a wire harness (electric wire). FIG. 4 illustrates the structure of a motor for use in an EPS. As shown in FIG. 4, a wire harness 52 is extended from the outer circumference of the bracket 53, in the motor 51. The EPS must perfectly protect the motor from water in its installation environment in which the EPS is provided near an axle. Hence, the wire harness 52 is attached to the bracket 53 with use of a rubber grommet 54.

[0005] The wire harness 52 is led out of the bracket 53 in a radial direction and is bent just subsequently at the top of the rubber grommet 54, as shown in FIG. 4, if the wiring direction of the harness further extends along the axial direction. If the harness must be wired on the side of a gear box 57, the harness is wired along the gearbox and fixed by a clamp 58 because the gear box 57 has some length extending in a direction toward a counter lock portion 61. Alternatively, if the harness is wired on the side of the motor 51, the wire harness 52 is bent as drawn by a broken line in FIG. 4, and is then fixed to a yoke 56 by a tape 59.

[0006] However, this motor 51 has a form that the wire harness 52 is led in a radial direction. Therefore, if the wire harness 52 is wired in the axial direction, the space occupied by the motor 51 increases due to a bending portion 55 of the wire harness. Suppose now that A is a minimum radius that can ensure air-tightness between the bracket 53 and the yoke 56 fixed thereto. A minimum radius necessary for installation of the wire harness 52 includes the wire-harness bending portion 55 and is therefore expressed by A+α. That is, an extra space is required for α in the periphery of the motor and hinders downsizing of the motor.

[0007] Meanwhile, if the wire harness 52 is bent and arranged in the axial direction, a gap may be created between the rubber grommet 54 and the bracket 53 or the wire harness 52 depending on how the harness is wired. If the wire harness 52 bent at the bending portion 55 is fixed by the clamp 58, the curvature R of the wire harness 52 and the clamping position are difficult to control. Consequently, an unnatural force acts between the rubber grommet and the bracket or the wire harness, like the foregoing case, so that air-tightness may be insufficient.

[0008] To prevent deterioration of sealing and ensure reliability of the motor 51, it may be necessary to reinforce the periphery of the rubber grommet 54 with a sealing material, depending on circumstances. A problem hence arises in that the production costs increase due to costs and processes for the sealing material. In particular, a silicone-based sealing material takes a long curing time, so that the items to be managed on a production line are increased to cause more costs.

SUMMARY OF THE INVENTION

[0009] The present invention has as its object to provide a motor in which a wire harness can be wired in an axial direction without bending the harness, to achieve downsizing and improved reliability of the motor and to reduce production costs.

[0010] According to the present invention, there is provided a motor comprising: an output shaft projecting from a first end side of the motor; a bracket installed in a second end side of the motor and having a brush holder containing a brush; and a power supply section provided on an end surface of the bracket in a first end side of the bracket, with a power supply line electrically connected to the brush and led from the power supply section along an axial direction of the output shaft.

[0011] In the motor according to the present invention, the wire harness is led not in the radial direction but in the axial direction. Therefore, wiring can be arranged in the axial direction without bending the wire harness. Accordingly, the necessary minimum radius of the motor can be reduced, and no extra space is required in the periphery of the motor. As a result, the motor can be downsized.

[0012] In the motor described above, the power supply section may include: a power supply terminal provided in the brush holder, electrically connected to the brush, and having an end portion extending in a direction toward the end surface of the bracket in the first end side of the bracket along the axial direction of the output shaft; a connection hole opened in the end surface of the bracket in the first end side, with the power supply terminal inserted from a second end side of the bracket in the connection hole; a terminal attached to the connection hole, fixed to the end surface of the bracket in the first end side of the bracket, connected to the power supply line, and having a joint terminal engaged with the power supply terminal; and an O-ring inserted between the terminal and the end surface of the bracket in the first end side of the bracket, to maintain air-tightness between the terminal and the bracket.

[0013] In this structure, wiring of the wire harness can be achieved by fixing the terminal to the bracket. Therefore, endurance of the power supply section can be improved. In addition, use of a rubber grommet at the power supply section can be repealed. Accordingly, a gap which will impair sealing is not created between the bracket and such a rubber grommet due to wiring of the wire harness. Therefore, it is unnecessary to reinforce the power supply section with a sealing material, so that costs and processes for such a sealing material can be saved. Thus, production costs can be reduced.

[0014] In the motor described above, the terminal may have a shield member which connects air-tightly the power supply line. In this structure, the inside of the terminal is maintained airtight against the external atmosphere as a so-called waterproof connector, and the joint terminal is contained air-tightly in the terminal.

[0015] In the motor described above, the O-ring may be provided at an end portion of the terminal, surrounding an opening of the connection hole, and may be pressed into contact with a flat end surface of the bracket. In this structure, the O-ring is pressed into contact with the flat end surface, so that the terminal can be fixed air-tightly to the bracket in a simple reliable structure owing only to the O-ring.

[0016] In the motor described above, the terminal may be secured to the bracket by a bolt. In this structure, the terminal is securely fixed to the bracket, so that endurance of the power supply section can be improved.

[0017] In the motor described above, the power supply terminal may be inserted in and connected to the joint terminal. Since an electric connection is completed only by an operation of inserting a component, an operation of assembling the power supply section is simplified so that man-hour of the operations can be reduced.

[0018] In the motor described above, an engaging portion may be provided between the terminal and bracket, and the power supply terminal and the joint terminal cannot be connected to each other with polarities of the power supply terminal and the joint terminal arranged in a direction different from a regular direction. In this structure, it is possible to prevent the power supply line from being assembled in a wrong direction.

[0019] In the motor described above, a counter lock portion may be provided, together with the power supply section, in the end surface of the bracket in the first end side of the bracket, and the counter lock portion may be engaged with a device to be driven, to which the output shaft is connected and rotation of the motor is transmitted. By providing the power supply section and the counter lock portion on one same surface, the wire harness extending in the axial direction can be fixed by a vertical clamp. Accordingly, reliability can further be improved.

[0020] In the motor described above, the motor may be used for an electric power steering apparatus. By using the motor, endurance and reliability of the electric power steering apparatus can be improved, and production costs can be reduced.

[0021] The above-described and other objects, and novel feature of the present invention will become apparent more fully from the description of the following specification in conjunction with the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

[0022]FIG. 1 is a side view showing an outer appearance of a motor according to an embodiment of the present invention;

[0023]FIG. 2 is a cross-sectional view of the motor shown in FIG. 1;

[0024]FIG. 3 is a front view of the motor shown in FIG. 1; and

[0025]FIG. 4 is an explanatory view showing the structure of a conventional motor used in an EPS.

DESCRIPTION OF THE PREFERRED EMBODIMENT

[0026] An embodiment of the present invention will now be described in detail on the basis of the drawings. FIG. 1 is a side view showing an outer appearance of a motor according to an embodiment of the present invention. FIG. 2 is a cross-sectional view of the motor shown in FIG. 1. FIG. 3 is a front view of the motor shown in FIG. 1.

[0027] The motor 11 shown in FIG. 1 is an electromagnetic motor and is used as a drive source of an electric power steering apparatus. The motor 11 has a cylindrical yoke 15, and plural permanent field magnets 16 are provided on the inner surface of the yoke. An armature 17 is rotatably provided inside the permanent field magnets 16. The armature 17 has a core 19 having plural slots 18 extending in the axial direction and coils 20 wound around the slots 18. The armature 17 is fixed to an output shaft 12 and is supported rotatably by bearings 21 a and 21 b.

[0028] A commutator 22 is provided in the left-hand side of the armature 17 in FIG. 2. The commutator 22 is fixed to an output shaft 12. A brush 23 contacts the surface of the commutator 22. The brush 23 is held in a brush holder unit 24. The brush holder unit 24 is contained on the side of the end surface 25 b (which is a second end surface) in the bracket 25, and is fixed to the bracket 25 by a screw 26. The bracket 25 is coupled with the yoke 15 by bolts 27.

[0029] The output shaft 12 is connected to an input shaft 46 of a gear box 45 by a joint 28. A counter lock portion 29 is projected and formed in the center of a first end surface 25 a of the bracket 25. The counter lock portion 29 is engaged with an installation hole 47 on the side of the gear box 45. The gear box 45 and the motor 11 are positioned relative to each other by the counter lock portion 29 and the installation hole 47, and then, the gear box 45 and the motor 11 are fixed by a bolt or the like.

[0030] Rotation of the output shaft 12 is appropriately decelerated in the gear box 45 and then transmitted to a pinion of a steering column. Rotation of the steering column is converted into reciprocation of a tie rod by a steering gear section of rack-and-pinion type, thus controlling wheels to be steered. As a driver operates a steering wheel, the motor 11 is driven in accordance with the steering angle, driving speed of a vehicle, and the like. Accordingly, the motor 11 supplies a steering assisting force. The driver can thus operate the handle with a small force.

[0031] In the motor 11, a power supply section 31 is provided on the end surface 25 a (which is the first end surface). A terminal unit 32 is attached to the power supply section 31. A wire harness 33 (which is a power supply line) is led out from the terminal unit 32 in the axial direction. That is, the power supply section 31 has a form in which the wire harness 33 is led not in a radial direction but in an axial direction. Therefore, wiring can be arranged in the axial direction without bending the wire harness 33, so that the necessary minimum radius of the motor 11 can be reduced due to non-existence of a bending portion. As a result, the motor 11 can be put in the range of the radius (2A) of the bracket 25, and no extra space is needed in the periphery of the motor. The motor can accordingly be downsized.

[0032] A joint terminal 34 connected to the wire harness 33 (power supply line) is contained in the terminal unit 32. A rubber shield (shield member) 36 is air-tightly attached to an end of the unit body 35 of the terminal unit 32. The wire harness 33 is inserted air-tightly in the rubber shield 36. As a result, the inside of the terminal unit 32 is kept airtight with respect to the external atmosphere, like a so-called waterproof connector. The joint terminal 34 is contained air-tightly in the terminal unit 32.

[0033] The terminal unit 32 is not constructed such that the wire harness 33 is sealed by a rubber tightening margin but is constructed such that the rubber shield 36 maintains air-tightness. Therefore, if only the layout of wiring the wire harness 33 can be ensured, a wire harness of any size can be attached by appropriately replacing the rubber shield 36. It is thus possible to respond easily to a request for increasing the core diameter.

[0034] A connection hole 37 is formed along the axial direction in the bracket 25. The connection hole 37 penetrates the bracket 25 and open in the end surface 25 a. An engaging portion 38 at the top end of the unit body 35 is inserted in the connection hole 37. As shown in FIG. 3, a joint portion 39 is projected and formed on the unit body 35, and is fixed to the end surface 25 a by bolts 41. An O-ring 43 is attached to an end surface 42 of the joint portion 39, surrounding the opening of the connection hole 37. The terminal unit 32 is fixed air-tightly to the end surface 25 a by the O-ring 43. At this time, the O-ring 43 is pressed into contact with the flat end surface 25 a. Therefore, the terminal unit 32 can be air-tightly fixed to the bracket 25 by a simple and high reliability structure of using only the O-ring 43.

[0035] Meanwhile, on the side of the end surface 25 b in the connection hole 37, a power supply terminal 44 electrically connected to the brush 23 is inserted. The power supply terminal 44 is provided at an end portion of a terminal plate formed integrally with the brush holder unit 24. The terminal plate is connected to the brush 23 via a pigtail, and the power supply terminal 44 is thus electrically connected to the brush 23. The power supply terminal 44 stands at right angles on the brush holder unit 24. The terminal 44 further extends toward the end surface 25 a along the extending direction (or axial direction) of the output shaft 12, and is contained in the connection hole 37.

[0036] When the terminal unit 32 is attached to the bracket 25, the power supply terminal 44 on the side of the bracket 25 is engaged with the joint terminal 34 on the side of the terminal unit 32. At this time, operations of inserting components and connecting them with bolts are completed. Thus, operations for assembling the power supply section 31 are so simple that man-hour of the operations can be reduced. In addition, the endurance of the power supply section 31 can be improved because the terminal unit 32 is fixed to the bracket 25 by bolts. Further, since the power supply section 31 does not use a rubber grommet, a gap which will impair sealing is not created between the bracket 25 and such a rubber grommet due to wiring of the wire harness 33. Accordingly, it is unnecessary to reinforce the power supply section 31 with a sealing material, so that costs and processes for such a sealing material can be saved. Thus, production costs can be reduced.

[0037] In the power supply section 31, the power supply terminal 44 is male while the joint terminal 34 is female. As shown in FIG. 2, both terminals are connected by inserting the power supply terminal 44 in the joint terminal 34. The wire harness 33 and the brush 23 are thus electrically connected so that an electric power can be supplied from a battery to the motor 11 via the wire harness 33.

[0038] The power supply section 31 thus adopts a connection method based on insertion of a terminal. Therefore, an electric connection can be made simply and steadily, without necessitating spot welding at the power supply section 31. As a result, stability in quality of products can be improved. In particular, there is no need of considering occurrence of sputtering owing to increase of the core diameter. Therefore, technical problems do not arise, and the number of items to be managed can be suppressed. Costs for increasing the core diameter can be reduced.

[0039] If the wire harness 33 is connected to the power supply terminal 44 by spot welding, the harness cannot be re-attached correctly after it is once attached in a wrong manner, for example, when + and − lines of the wire harness 33 have different lengths. However, this problem need not be cared in the power supply section 31 according to the present embodiment. In this case, an engaging portion may be provided between the terminal unit 32 and the bracket 25, such that the terminal unit 32 and the bracket 25 can be coupled only in a regular direction. Then, the wire harness can be prevented from being attached in a wrong manner.

[0040] After thus attaching the terminal unit 32 to the bracket 25, the wire harness 33 is fixed to a side portion of the gear box 45 by the clamp 48. In the motor 11, the power supply section 31 and the counter lock portion 29 are provided on one same surface. Therefore, the wire harness 33 extending in the axial direction without skewing can be fixed by a vertical clamp. Accordingly, the curvature R of the wire harness 52 need not be managed, and the clamp position can be managed easily. In addition, vertical clamping which is ideal for a harness clamp is realized, so that holding ability of the wire harness 33 can be improved and reliability can further be improved.

[0041] Detailed description has hereinabove been given of the invention achieved by the present inventor with reference to the embodiment. However, the present invention should not be limited to the embodiment described above, and may be variously modified within the scope not departing from the gist.

[0042] The above embodiment has been described with reference to an example in which the motor according to the present invention is applied to an electric power steering apparatus. However, the motor can be applied to other electrical rotary devices. For example, the motor according to the present invention is effective for other in-vehicle motors and engines (power generators) for cars, and motors and power generators for use in industrial machines, home electric appliances, IT devices, etc.

[0043] In the motor according to the present invention, a power supply section from which a wire harness is led along the axial direction is provided on one end surface of the bracket. Therefore, wiring can be arranged in the axial direction without bending the wire harness, so that the necessary minimum radius of the motor can be decreased. Accordingly, an extra space such as a bending portion of the wire harness is not required in the periphery of the motor. The motor can thus be downsized.

[0044] The power supply section is constructed in a structure which includes a power supply terminal provided in a brush holder and extending in the axial direction, a connection hole opened at one end surface of a bracket to contain the power supply terminal, a terminal unit to be attached to the connection hole, connected to the wire harness, and having a joint terminal engaged with the power supply terminal, and an O-ring interposed between the terminal unit and the end surface of the bracket. As a result, the wire harness can be wired by fixing the terminal to the bracket, so that endurance of the power supply section can be improved. In addition, use of a rubber grommet at the power supply section can be repealed. Therefore, a gap which will impair sealing is not created between the bracket and such a rubber grommet due to wiring of the wire harness. Accordingly, it is unnecessary to reinforce the power supply section with a sealing material, so that costs and processes for such a sealing material can be saved. Thus, production costs can be reduced.

[0045] Further, the power supply section and a counter lock portion are provided on one same end surface of the bracket. Therefore, the wire harness extending in the axial direction can be fixed by a vertical clamp. Accordingly, vertical clamping which is ideal for a harness clamp can be realized, so that holding ability of the wire harness is improved and reliability is further improved. 

What is claimed is:
 1. A motor comprising: an output shaft projecting from a first end side of the motor; a bracket installed in a second end side of the motor and having a brush holder containing a brush; and a power supply section provided on an end surface of the bracket in a first end side of the bracket, with a power supply line electrically connected to the brush and led from the power supply section along an axial direction of the output shaft.
 2. The motor according to claim 1, wherein the power supply section includes: a power supply terminal provided in the brush holder, electrically connected to the brush, and having an end portion extending in a direction toward the end surface of the bracket in the first end side of the bracket along the axial direction of the output shaft; a connection hole opened in the end surface of the bracket in the first end side, with the power supply terminal inserted from a second end side of the bracket in the connection hole; a terminal attached to the connection hole, fixed to the end surface of the bracket in the first end side of the bracket, connected to the power supply line, and having a joint terminal engaged with the power supply terminal; and an O-ring inserted between the terminal and the end surface of the bracket in the first end side of the bracket, to maintain air-tightness between the terminal and the bracket.
 3. The motor according to claim 2, wherein the terminal has a shield member which connects air-tightly the power supply line.
 4. The motor according to claim 2, wherein the O-ring is provided at an end portion of the terminal, surrounding an opening of the connection hole, and is pressed into contact with a flat end surface of the bracket.
 5. The motor according to claim 2, wherein the terminal is secured to the bracket by a bolt.
 6. The motor according to claim 2, wherein the power supply terminal is inserted in and connected to the joint terminal.
 7. The motor according to claim 2, wherein an engaging portion is provided between the terminal and bracket, and the power supply terminal and the joint terminal cannot be connected to each other with polarities of the power supply terminal and the joint terminal arranged in a direction different from a regular direction.
 8. The motor according to claim 1, wherein a counter lock portion is provided, together with the power supply section, in the end surface of the bracket in the first end side of the bracket, and the counter lock portion is engaged with a device to be driven, to which the output shaft is connected and rotation of the motor is transmitted.
 9. The motor according to claim 1, wherein the motor is used for an electric power steering apparatus. 